Formation of cables



July 23, 1935. A, ROSNER FORMATION OF CABLES Original Filed March 18,1929 4 Sheets-Sheet l INVENTOR. fldo/ph Pas/oer BY M W. 6

ATTORNEY July 23, 19350 A. ROSNER FORMATION OF GABLES Original FiledMarch 18, 1929 4 Sheets5heet 2 I INVENTOR. Hdo/pn Eosner BY iwm '5ATTORNEY.

July 23, 1935. y L N R 2,009,208

FORMATION OF CABLES Original Filed March 18, 1929 4 Sheets-Sheet 3INVENTOR. Hdo/ph [Posner BY f A TTORNEY July 23, 1935. A.. ROSNER2,009,208

FORMATION OFCABLES Original Filed March 18, 1929 4 Sheets-Sheet 4 {fig26 r 4 E Q A V V INVENTOR. Hdo/ph Posner BY W yaleox A TTORNEY,

Patentecl July 23, 1935 UNITED STATES PATENT OFFICE FORMATION OF CABLES-Adolph Rosner, Rockton, 111., assignor, by mesne assignments, to BendixBrake Company, South Bend, but, a corporation of Illinois 3 @lairus.

the flaring out or brooming of the strands that would ensue, should thecable be cut by ordinary methods.

A further object of the invention is to provide an anchor or attachmentportion on the ends oi the cable formed by my novel severing process andto this encl the ends in their heated. state may be then upset insuitably shaped cites. The ends may also he provided with supplementalfittings by providing the cable with a sleeve and then severing andupsetting the severed ends to provide the desired end enlargements.

In carrying out my novel cutting operation either with or without thesupplemental sleeve, the area to be severed is preferably clampedhetween spaced electrodes or other suitable clamplng chucks andsubsequently heated to a ma leable state. The clamps are then separatedwith the heating continued, which results in both drawing out and fusionof the center of the tensioned area, ultimately resulting in thedesirecl rupture. F

Further features of the invention relate to a method of preforming oneend of a flexible cable; to specific couplings securing together the calargecl ends oi the cable sections; to novel connections between theenlarged caole ends and rigid power transmission elements; and tovarious other details of construction and combinations of partsparticularly set forth in the following descriptive matter and shown inthe accompany-= lug drawings, in which:

Figure l is a side elevation oi? one form of apparatus for effecting mysevering process;

Figures 2 and 3 show respectively the twisting and ultimate severing ofthe cable;

Figure l shows the condition of the cable after being cut by the usualmeans;

Figure 5 shows the newly formed end of one section of the cableresulting from my novel severing process;

as Figure 6 is a longitudinal sectional view similar (Clu Elfi -3) toFigure 3 indicating the electrodes :Zormcd with shaping dies;

Figures '7 and 8 are longitudinal sectional views showing respectivelythe initial positioning: of the shaping plunger and its ultimateposition in shaping the cable ends;

Figures 9 and 10 show two forms of cable ends fashioned by the inventiondescribed herein;

Figures 11, 12, and 13 are similar to the process steps indicated inFigures 5, 7, and 8, the cable ends in this case being covered. bysleeves to he upset;

Figure 1 shows the product resulting process indicated in Figures ll,12,,ancl

Figure 15 indicates in section the apparatus and work for effecting theproduct shown in F ure 16;

Figure 16 cliscl formed by the Figures it other manner 0 tially shown in'Figiu'es 20 and 21 show ratus for preicrnlhig the stailec". product;

Figures 22, 22A, 23, anti sl'row, in section, means for connecting novelheadec. cable to one end oi a lever;

Figures 25, 26, 27, alllfi 23 show another form lever connection; and 20Figures 29 and so show types o unto or connecting the cable end-lsSllOWR in u-igurc- Q and it.

As disclosed in Figure l, a multi s raoue-ci hell caily wound. highcec'bon steel cable is clamped by spaced relatively movable two-pantelectrodes 52 and is. Electrode t2, shown the form. of a split boss, ispreferably rigidly secured to one end of a croolzecl extension l8 of alead screw to threaded into a standard 22. Electrode M which isstationary, is preferably supported by a stamlarc 2t insulated at 23. Atwo-part refractory shield may he encircled about the cable hetween theclamps to obviate oxidation during the heating of the cable.

The cable to co severed. is first positioned within the electrode clampsand thence threaded into an aligned insulated opening in the lead screw.A heating current or" relatively high amperage and low voltage is thenpassed through the work which is progressively cooled by the electrodes,which may he water-cooled, from points A and E, Figure l, to thegeometrical center of the work. when the cable section between theelectrodes is sufficiently hot to be easily drawn, the lead screw isslowly rotated by handle 26, effecting a concable one.

tralized twisting and tensioning of the section, as shown in Figure 2.Continued drawing reduces the cross section of the cable, whichautomatically increases its electrical resistance, resulting inincreased heating of the reduced section. Fusion of the area of leastcross section is thus quickly efiected, which results in its ultimaterupture, as indicated in. Figure 3. A resultant arcing of the currentalso increases the temperature of the fused area to aid in effecting ahomogeneous integral cable end.

A very effective and expeditious severing prosess is thus carried out,resulting in a product well suited for its purposes. The slight tapermade possible by the combined torsional and tensile stresses rendersunnecessary any bufiing off of the irregularities of the fused end, inview of the reduced diameter thereof. The twisting retains the originaltight contact or wrap of the individually tapered wire strands and inthis connection it is important to note that the hand of the lead screw29 must be such as to agree with the hand of the pitch of the cablestrands to effect this result. Furthermore the fusion of the endobviates the brooming effect or spreading out of the tensioned helicalwires of the cable which would ordinarily result with manual cutting.This result is clearly shown in Figure 4. The cable core 28 of Figure 4is normally drawn out or tensioned by the tight wound helical cover andwith 7 ordinary cutting tends to draw within the end of the cover. By myprocess, however, this is obviated inasmuch as the end of the core isfused with the ends of the wire cover.

The twisting of the area to be separated may be dispensed with byslightly modifying the apparatus of Figure 1 to provide only translatorymotion to the movable heating and clamping unit i2. cables may besimultaneously severed by arranging a plurality of the heating units ofFigure 1 in tandem. I

The above described severing process may be employed in providing cablesections with enlarged or headed ends, which ends may then be connectedby novel unions to be described hereafter or one of said enlarged endsmay besecured to one end of a lever or equivalent rigid powertransmission member.

In that embodiment of my invention disclosed in Figures 6, '7 and 8,electrodes H2 and I may each be provided with shaping dies 30 havingbores shaped as desired to fashion the ultimate product. The cable isfirst clamped into the electrodes which may be in two parts as shown inFigure 1. The work is then heated and electrode H2 moves away fromelectrode III, which is preferably stationary, resulting in the ruptureof the cable as previously described. While the cable ends are stillhot, a floating plunger 32 or heading die is dropped between the diemembers and the movable electrode H2 is then closed upon the plunger andstationary electrode, resulting in shaping the ends as disclosed inFigure 8. As disclosed in Figures 9 and 10, various shaped cable endsmay be fashioned depending upon the respective contours of the die andplunger ends.

In lieu of the cable ends formed in the manner just described, I mayprovide supplemental fittings on the ends as disclosed in the processset forth in Figures 11 to 13, inclusive. The relatively movableelectrodes 2 and 2 may each be provided with hemispherical dies 84.Clamped in the electrodes are the ends of a sleeve member 36 such asshown in Figure 15, which sleeve It is also contemplated thata-plurality of aocaaoa surrounds the cable to be severed. The work isthen electrically heated and severed in a manner previously describedand then shaped by the heading die 31 as indicated in Figures 12 and 13to effect the product shown in Figure 14. As previously described, thedies and plunger may be shaped to eiiect the desired contour of thecable end.

If a single enlargement or protuberance is desired in a COIltlIlllOlBcable, the relatively movable electrodes 38 and Q0 of Figure 15 areclosed upon the heated sleeved cable 42 to upset the same as indicatedin Figure 16. The same process might also be employed to form anenlargement on a rigid member.

In Figures 17, 18, and 19 a modified form of process for forming theenlarged cables end is disclosed. As here disclosed the sleeve of Figure15 is lengthened to extend through the stationary electrode 33. The workis then heated and upset by movable electrode 541 to form theenlargement 36 shown in Figure 17. The work is then transferred to thespecially shaped movable electrode 68 which receives the enlargedportion 46. The process of heating and upsetting thehwork between theelectrodes is then repeated, as shown in Figure 18, and the resultingproduct transferred to the clamping electrodes 52 and 5d of Figure 19 tobe heated and severed in the manner described heretofore.

*The dies heretofore described may be watercooled-so that in the processof upsetting the heated portion of the work, the cold die will bring vabout a quenching efiect, this hardening to a certain extent the steelin the headed ends of the cable. A rigid member might also besubstituted for the flexible cable member to be severed or headed.

In applying a flexible multi-stranded highly tensioned steel cable to acurved lever such as shown in Figure 21, it is desirable to preform thecable to the desired curve. This will give a set to the strands holdingthe same in place and obviating the wear that would otherwise ensue dueto the relative sliding motion of the strands on oneanother duringflexing. I accordingly suggest that the cable be first bent into thedesired shape which will effect the slanting end 56 as indicated indotted lines in Figure 20. The curvature of the cable is retained by atwo-part stationary electrode 58 which clamps the cable with its sleevetil in the desired position. A movable electrode 62 is then clampedabout the extreme end of the sleeve and cable, the work heated and thenupset by relative motion of the electrode. The resulting product is aheaded cable end, which head retains the desired curvature of the cable,preventing the wires thereof from slipping back to their normalposition.

As shown in Figure 21, the preformed cable just described may be fittedwithin the peripheral groove of a lever 63, which lever is so shapedthat the angle of motion which the lever described in operation does notchange the alignment of the cable in the conduit Bl, thus eliminatingwear. In other words, with revolution of the lever the cable is drawnout of its conduit in a. straight line, thisbeing made possible bymaking the groove a portion of the circumference of a circle having itscenter coinciding with the axis of rotation of the lever.

The headed end of the cable disclosed in either Figures 14 or 19 may besecured to the radially slotted end of a rigid lever member 88. Theenlargement preferably rests against a seat in the 7 form of a plainfaced washer 68 which in turn bears against an embossed-washer 10 whichin turn bears against a plain washer 1| contacting the base of thecylindrical recess in the lever end. A compression spring 12 confinedbetween stops 1] and H, the latter contacting cable enlargements 16,serves to retain the cable end in its seat.

A modified connection is shown in Figure 23 wherein the enlargement I8is provided with a relatively long sleeve 19 passing through theradially slotted end of the lever 8|), a compression spring 82, confinedbetween the flanged end 84 of the sleeve and a stop 86 abutting thelever, serving to retain the cable end in its seat. With bothmodifications just described the cable end has a substantially universalaction, the ball and socket connection as well as the swiveling actionof the embossed washers Hi facilitating this movement.

As disclosed in Figures 25 to 28, inclusive, the ball-shaped end of thecable of Figure 19. may be secured to the radially slotted lever end 88,the ball being seated within a correspondingly shaped recess in thelever end and secured in place by a U-shaped clip 90 seated within agroove 92 in the end of the cable and having its inturned ends 94 seatedwithin recesses in the lever end.

The headed cable ends of Figures 9 and 10 may be connected in the mannerdisclosed in Figures 29 and 30. The gland nuts 96 of Figure 29 may beslipped over the cable prior to the forming of the integral heads 98.and are secured in place on the said heads by right and left threadedlock nut I00. As shown in Figure 30 the headed cable may be connected toa rigid member I02 such as a brake rod, the gland nut "M in thisconstruction having a relatively long interiorly threaded shank toadjustably receive the threaded end of the rod I02. Acheck nut I06 maybe used, being threaded on the rod IN into engagement with the end ofthe shank.

While several illustrative embodiments have been described in detail, itis not my intention to limit the scope of the invention to thoseparticular embodiments, or otherwise than by the terms of the appendedclaims. Part of the subject-matter herein disclosed is claimed in mydivisional application No. 747,757, filed October 10, 1934, as well asin my above-mentioned parent application 347,882 and in my companiondivisional Case 646,726, filed December 10, 1932.

I claim:

1. That method of forming an enlargement on a power transmission memberwhich comprises placing a sleeve on a section of the member, clampingsaid sleeved portion in spaced electrodes, heating :the work between theelectrodes to a malleable state and moving the electrodes toward eachother to upset said cable and sleeve to form the desired enlargement.

2. The herein described method of forming cable .ends which comprisesclamping the sleeved portion of a transmission member in electrodemembers, heating and upsetting the workto form an enlargement, clampingsaid enlargement in a third electrode, again heating and upsetting thesleeved cable clamped between said third electrode and one of thefirst-mentioned electrodes, clamping the spaced enlargements thus formedin a pair of electrode clamps, and then heating and severing theconnection between said enlargements to provide the desired cable ends.

3. That method of preforming the end of a multi-stranded cable whichcomprises inserting a sleeve member over the ,extreme end of said cable,bending the end and clamping the end so bent in relatively movablespaced electrodes, heating the work between said electrodes and thenupsetting the sleeved cable so heated to provide an enlargement whichretains the several strands of the cable in their bent condition.

ADOLPH ROSNER.

